Hybrid tanks

ABSTRACT

A commercial hybrid tank includes a metal liner with an upper wall and a lower wall. The upper wall and the lower wall define a cavity therebetween. A weld joint joins the upper and lower walls together. A fiber winding layer is wrapped around an outer surface of the metal liner. A method for manufacturing a commercial hybrid tank includes overlapping surfaces of an upper wall and a lower wall to form a metal liner defining a cavity. The method includes joining the surface of the upper wall and the surface of the lower wall together by welding to form a weld joint between the upper wall and the lower wall. The method includes wrapping the metal liner with a fiber winding layer around an outer surface of the metal liner to form a hybrid tank.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Continuation application and claims priority toand the benefit of U.S. application Ser. No. 16/659,861 filed on Oct.22, 2019, which is a Continuation application and claims priority to andthe benefit of U.S. application Ser. No. 15/367,911 filed on Dec. 2,2016. The entirety of such application is incorporated herein byreference.

BACKGROUND 1. Field of the Invention

The present invention generally relates to well and expansion tanks and,more particularly, to commercial well and expansion tanks.

2. Description of Related Art

Many well and expansion tanks use a diaphragm or bladder to separate airfrom water. An air charge pressure on one side keeps thediaphragm/bladder at a distance away from the inside wall of the tank inthe air dome. When the tank is installed onto a water system, the watersystem pressure pushes back against the diaphragm/bladder, compressingthe air. The proper pre-charge will continue to keep thediaphragm/bladder away from the tank wall. If the pre-charge pressure isnot enough to provide an air volume appropriate for the water supplypressure, the diaphragm/bladder will fill the air cell. If eventuallythe diaphragm/bladder “bottoms out” on the tank wall, the tank becomesineffective in the function it has been designed to provide. An exampleof a non-metallic conventional expansion tank assembly is provided inU.S. Pat. No. 7,216,673 to Gremour et al. Gremour et al. discloses anon-metallic, diaphragm-type tank assembly for use with a pressurizedwater system. The disclosure of U.S. Pat. No. 7,216,673 to Gremour etal. is incorporated by reference herein in its entirety. Otherconventional expansion tanks can be made from metal, as described inU.S. Pat. No. 7,287,663 to Vandal et al. The disclosure of U.S. Pat. No.7,287,663 to Vandal et al. is incorporated by reference herein in itsentirety.

Some tanks, defined as type III tanks, can have a metal liner with fiberwinding around the metal liner. Traditional Type III composite tanks areused in consumer applications, e.g. personal use gas cylinders. Anexample of a consumer Type III tank is provided in U.S. Pat. No.7,255,245 to Oliveira et al. The disclosure of U.S. Pat. No. 7,255,245to Oliveira et al. is incorporated by reference herein in its entirety.Traditional Type III tanks have been considered satisfactory for theirintended purpose, however, there is ongoing need in the art for improvedType III tanks.

SUMMARY

A commercial hybrid tank includes a metal liner with an upper wall and alower wall. The upper wall and the lower wall define a cavitytherebetween. A weld joint joins the upper and lower walls together. Afiber winding layer is wrapped around the outer surface of the metalliner.

In accordance with some embodiments, the metal liner has an outerdiameter ranging from 11 to 26 inches. A ratio of a wall thickness ofthe metal liner to the outer diameter of at least one of the upper wallor lower wall can range from 0.0028 to 0.0032. The tank can have apressure rating of up to 300 psi at 240° F. The tank can withstand ahydrostatic pressure test of five times its pressure rating at 240° F.

The liner can define a longitudinal liner axis. The fiber winding layercan be formed of fiber windings helically and circumferentially wrappedwith respect to the longitudinal liner axis around the outer surface ofthe liner. The tank can include a flexible diaphragm positioned withinthe cavity connected to an inner diameter surface of the lower wall. Thediaphragm can separate the cavity into an upper portion and a lowerportion. The upper portion of the cavity can be sealed to contain apressurized gas and the lower portion is sealed to contain a pressurizedliquid. The tank can include an inner hoop ring operatively connected toan inner surface of the flexible diaphragm to hold the flexiblediaphragm in place against the lower wall.

The upper wall can include an upper dome and a dome extension and/or acylindrical extension. The weld joint can be a first weld joint and theupper wall can include a second weld joint defined between the upperdome and either the dome extension or the cylindrical extension bondingthe upper dome to the dome extension or the cylindrical extension. Thefirst weld joint can be defined between at least one of the domeextension or the cylindrical extension of the upper wall and the lowerwall of the liner. The weld joint can include a weld bead. The weld beadcan extend radially outward from the outer surface of the metal liner0.125 inches or less.

In some embodiments, the liner includes an opening with a connectorpositioned therein. The connector can be defined in the upper wall ofthe liner. The connector can include a central collar operativelyconnected to the opening of the liner. The central collar can define alongitudinal axis and an axial passage. A support plate can be nestedwithin the opening of the liner axially below the central collar. Thesupport plate can include a hole defined therein. The connector caninclude an air stem extending from the hole of the support plate throughthe axial passage of the central collar. The connector can be defined inthe lower wall of the liner. The lower wall can include a lower dome.

In accordance with another aspect, a method for manufacturing acommercial hybrid tank includes overlapping surfaces of an upper walland a lower wall to form a metal liner defining a cavity. The methodincludes joining the surface of the upper wall and the surface of thelower wall together by welding to form a weld joint between the upperwall and the lower wall. The method includes wrapping the metal linerwith a fiber winding layer around an outer surface of the metal liner toform a hybrid tank.

In accordance with some embodiments, wrapping the metal liner with thefiber winding layer includes applying a pressure to the metal liner fromwithin the cavity to oppose forces applied to the outer surface of themetal liner during wrapping. The pressure applied to the metal linerfrom within the cavity can be greater than 50 psi. The metal liner candefine a longitudinal liner axis. Wrapping the metal liner with thefiber winding layer can include wrapping the fiber winding layerhelically and circumferentially with respect to the longitudinal lineraxis around the outer surface of the liner. The method can includepriming the outer surface of the metal liner before wrapping the metalliner with the fiber winding layer. The method can include heat curingthe hybrid tank after wrapping the metal liner with the fiber windinglayer.

These and other features of the systems and methods of the subjectinvention will become more readily apparent to those skilled in the artfrom the following detailed description of the embodiments taken inconjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

So that those skilled in the art to which the subject inventionappertains will readily understand how to make and use the devices andmethods of the subject invention without undue experimentation,embodiments thereof will be described in detail herein below withreference to certain figures, wherein:

FIG. 1 . is a perspective view of a portion of an embodiment of a fluidtank constructed in accordance with the present disclosure, showingupper and lower walls of the liner welded together;

FIG. 2 is a partial cross-sectional view of the fluid tank of FIG. 1 ,showing the flexible diaphragm positioned within the cavity connected toan inner diameter surface of the lower wall;

FIG. 3 is a perspective view of the fluid tank of FIG. 1 , showing thefluid tank with circumferential and helical fiber windings around theouter surface of the liner;

FIG. 4 is a perspective view of the fluid tank of FIG. 1 , showing thefluid tank with circumferential and helical fiber windings around theouter surface of the liner; and

FIG. 5 is a flowchart of an exemplary method for assembling a fluid tankin accordance with an embodiment of the present disclosure, showingoperations joining the liner together.

DETAILED DESCRIPTION

Reference will now be made to the drawings wherein like referencenumerals identify similar structural features or aspects of the subjectinvention. For purposes of explanation and illustration, and notlimitation, a partial view of an exemplary embodiment of the commercialhybrid tank in accordance with the invention is shown in FIG. 1 and isdesignated generally by reference character 100. Other embodiments ofthe tank 100 in accordance with the invention, or aspects thereof, areprovided in FIGS. 2-5 as will be described.

As shown in FIGS. 1 and 2 , commercial hybrid fluid tank 100 includes ametal liner 102 defined by an upper wall 104 and a lower wall 106. Afiber winding layer 151, shown in FIG. 2 , is around an outer surface109 of metal liner 102, therein creating the hybrid (combination ofmetal and fiber) tank. Fiber winding layer 151 provides resistance tointernal pressure such that metal liner 102 can be thinner, creating alighter weight fluid tank 100. Commercial hybrid tank 100 can be usedin, for example, a commercial boiler or water system. Liner 102 definesa longitudinal liner axis A. Upper wall 104 and lower wall 106 define acavity 114 there between. A weld joint 105 joins upper and lower walls,104 and 106, respectively, to form a hermetically sealed joint therebetween. Upper wall 104 includes an upper dome 115 and a dome extension117. It is contemplated that dome extension 117 can also be acylindrical extension. Those skilled in the art will readily appreciatethat depending on the desired length of the tank, any number of domeextensions 117 or other cylindrical extensions can be used. Or, domeextension 117 can be omitted and upper dome 115 can be welded directlyto lower wall 106.

With continued reference to FIGS. 1 and 2 , weld joint 105 is a firstweld joint 105 and upper wall 104 includes a second weld joint 107defined between upper dome 115 and dome extension 117 bonding upper dome115 to dome extension 117. First weld joint 105 is defined between domeextension 115 of upper wall 104 and lower wall 106 of liner 102. Weldjoints 105 and 107 include a respective weld bead 111. Weld beads 111extend radially outward from outer surface 109 of the metal liner 0.125inches or less. This limit assists with creating a transition for thefiber winding layer 151 and tends to reduce gaps from forming betweenmetal liner 102 and fiber winding layer 151, which may lead to movementof metal liner 102 when tank 100 is under internal pressure.

As shown in FIG. 2 , fluid tank 100 includes flexible diaphragm 118positioned within cavity 114 connected to an inner diameter surface 120of lower wall 106. Diaphragm 118 separates cavity 114 into upper portion122 and a lower portion 124. Upper portion 122 of cavity 114 is sealedto contain a pressurized gas and lower portion 124 is sealed to containa pressurized liquid. Fluid tank 100 includes an inner hoop ring 126operatively connected to an inner surface 128 of flexible diaphragm 118to hold flexible diaphragm 118 in place against lower wall 106. Lowerwall 106 includes a hoop groove 112 that mates with inner hoop ring 126to pinch flexible diaphragm 118 between the hoop groove 112 of lowerwall 106 and inner hoop ring 126. Liner 102 includes an opening 116 witha connector 130 positioned therein. Connector 130 is defined in upperwall 104 of the liner 102. Connector 130 includes a central collar 132operatively connected to opening 116 of liner 102. Central collar 132defines a longitudinal axis, the same as axis A, and an axial passage140. A support plate 134 is nested within opening 116 of the liner 102axially below central collar 132. Support plate 134 includes a hole 136defined with an air stem 138 extending therethrough and through axialpassage 140 of central collar 132. A water connector 133 is defined inlower wall 106 of the liner 102.

As shown in FIG. 2 , in some embodiments, tank 100 can include an innerlower plastic liner 113 that corresponds to the shape of lower wall 106.The lower plastic liner 113 is disposed radially between diaphragm 118and lower wall 106 and is simultaneously held by inner hoop ring 126 toform a corrosion resistant volume in lower portion 124 for thepressurized liquid in an open fluid system condition, e.g. for potablewater applications.

With continued reference to FIGS. 1 and 2 , metal liner 102 has an outerdiameter D ranging from 11 to 26 inches. A ratio of a wall thickness tof metal liner 102 to outer diameter D of at least one of upper wall 104or lower wall 106 ranges from 0.0028 to 0.0032. For example, tank 100with an outer diameter of 26 inches can have a thickness of 0.073inches, tank 100 with a diameter of 22 inches can have a thickness of0.062 inches, tank 100 with an outer diameter of 15 inches can have athickness of 0.043 inches, and tank 100 with an outer diameter of 11inches can have a thickness of 0.035 inches. Tank 100 has a pressurerating of up to 300 psi at 240° F. Metal liner 102 alone has rating of125 psi at 240° F. and has a burst strength that is higher than themaximum 300 psi rating. Tank 100 is configured to withstand ahydrostatic pressure test of five times its pressure rating at 240° F.,for example, 1500 psi at 240° F.

As shown in FIGS. 3 and 4 , fiber winding layer 151 is formed of fiberwindings 153 helically and circumferentially wrapped with respect to thelongitudinal liner axis A around outer surface 109 of liner 102.Wrapping fiber winding layer 151 around metal liner 102 (combined withthe thinner deep drawn upper and lower walls 104 and 106 of liner 102)allows for a light-weight pressure vessel with reduced material cost.For example, it can be up to sixty-percent lighter than traditionalcommercial water tanks that are typically just constructed from metal.Fiber winding layer 151 also assists in resisting corrosion of the metalliner 102 and assists in insulating metal liner 102 to reduce heat lossin a boiler application. It also assists with ease of installation dueto the reduced weight as compared with standard commercial pressurevessels. Metallic liner 102 and fiber winding layer 151 work together toproduce a higher maximum working pressure tank than traditionalcommercial tanks that only include steel liners. Tank 100 may beconstructed in a horizontal or vertical configuration with ratings up to300 psi at 240° F. Fiber winding layer 151 includes multiple layers offiber windings 153 that are helically and circumferentially wrapped withrespect to a longitudinal axis A of liner 102. FIG. 3 shows tank 100partially wrapped with fiber winding layer 151. FIG. 4 shows tank 100 inan almost completed form with helical wrappings completed andcircumferential wrapping is in process.

As shown in FIG. 5 , a method 200 for manufacturing a commercial hybridtank, e.g. tank 100, includes overlapping surfaces of an upper wall,e.g. upper wall 104, and a lower wall, e.g. lower wall 106, to form ametal liner, e.g. metal liner 102, defining a cavity, e.g. cavity 112,as shown schematically by box 202. Method 200 includes joining thesurface of the upper wall and the surface of the lower wall together bywelding to form a weld joint, e.g. weld joint 105, between the upperwall and the lower wall, as shown schematically by box 204.

With continued reference to FIG. 5 , method 200 includes priming theouter surface of the metal liner before wrapping the metal liner with afiber winding layer, e.g. fiber winding layer 151, as shownschematically by box 206. Method 200 includes wrapping the metal linerwith the fiber winding layer around an outer surface, e.g. outer surface109, of the metal liner to form the hybrid tank, as indicatedschematically by box 208. Wrapping the metal liner with the fiberwinding layer includes applying a pressure to the metal liner fromwithin the cavity to oppose forces applied to the outer surface of themetal liner during wrapping, as shown schematically by box 210. Thepressure applied to the metal liner from within the cavity is greaterthan 50 psi. Wrapping the metal liner with the fiber winding layerincludes wrapping the fiber winding layer helically andcircumferentially with respect to the longitudinal liner axis around theouter surface of the liner, as shown schematically by box 212. Method200 includes heat curing the hybrid tank after wrapping the metal linerwith the fiber winding layer, as shown schematically by box 214.

The methods and systems of the present invention, as described above andshown in the drawings, provide for commercial well and boiler tanks withsuperior properties including reduced manufacturing costs, improveddurability, reduced weight, increased corrosion resistance, and improvedperformance in outdoor environments. While the apparatus and methods ofthe subject invention have been shown and described with reference tocertain embodiments, those skilled in the art will readily appreciatethat changes and/or modifications may be made thereto without departingfrom the spirit and scope of the subject invention.

What is claims is:
 1. A method of manufacturing a tank, comprising:overlapping surfaces of an upper wall and a lower wall to form a metalliner that defines a cavity and having an outer surface; joining asurface of the upper wall and a surface of the lower wall together bywelding to form a weld joint; positioning a diaphragm within the cavityand connecting to an inner diameter surface of the lower wall, thediaphragm separating the cavity into an upper portion and a lowerportion, wherein the upper portion is for a gas and the lower portion isfor a liquid; priming an outer surface of the metal liner; wrapping themetal liner with a fiber winding layer around the outer surface; andapplying a pressure to the metal liner from within the cavity to opposeforces applied to the outer surface of the metal liner during the stepof wrapping the metal liner.
 2. The method of claim 1, furthercomprising wrapping the fiber winding layer helically andcircumferentially with respect to the longitudinal liner axis around theouter surface of the liner.
 3. The method of claim 2, further comprisingheat curing the hybrid tank after wrapping the metal liner with thefiber winding layer.
 4. The method claim 1, further comprising disposinga plastic liner radially between the diaphragm and the lower wall,wherein the plastic liner corresponds in shape to the lower wall and issecured by an inner hoop ring to form a corrosion resistant volume inthe lower portion for the liquid for a potable water application.
 5. Themethod of claim 1, further comprising positioning a connector within anopening on the upper wall, wherein the connector includes a collar thatdefines a longitudinal axis and an axial passage to allow the air toenter the cavity.
 6. The method of claim 1, further comprising defininga water connector in the lower wall to allow water to enter the cavity.7. The method of claim 1, wherein the weld joint includes a weld beadextending radially outward from the outer surface of the metal liner nomore than approximately 0.125 inches.
 8. A method of manufacturing atank, comprising: deep drawing an upper wall and a lower wall;overlapping surfaces of the upper wall and the lower wall to form ametal liner that defines a cavity and has an outer surface; joining asurface of the upper wall and a surface of the lower wall together bywelding to form a weld joint; positioning a diaphragm within the cavityand connecting to an inner diameter surface of the lower wall, thediaphragm separating the cavity into an upper portion and a lowerportion; priming an outer surface of the metal liner; wrapping the metalliner with a fiber winding layer around the outer surface; and applyinga pressure to the metal liner from within the cavity to oppose forcesapplied to the outer surface of the metal liner during the step ofwrapping the metal liner.
 9. The method of claim 8, further comprisingwrapping the fiber winding layer helically and circumferentially withrespect to the longitudinal liner axis around the outer surface of theliner.
 10. The method of claim 9, further comprising heat curing thehybrid tank after wrapping the metal liner with the fiber winding layer.11. The method claim 8, further comprising disposing a plastic linerradially between the diaphragm and the lower wall, wherein the plasticliner corresponds in shape to the lower wall and is secured by an innerhoop ring to form a corrosion resistant volume in the lower portion forthe liquid for a potable water application.
 12. The method of claim 8,further comprising positioning a connector within an opening on theupper wall, wherein the connector includes a collar that defines alongitudinal axis and an axial passage to allow the air to enter thecavity.
 13. The method of claim 8, further comprising defining a waterconnector in the lower wall to allow water to enter the cavity.
 14. Themethod of claim 8, wherein the weld joint includes a weld bead extendingradially outward from the outer surface of the metal liner no more thanapproximately 0.125 inches.
 15. A method of manufacturing a tank,comprising: overlapping surfaces of an upper wall and a lower wall toform a metal liner that defines a cavity and having an outer surface;joining a surface of the upper wall and a surface of the lower walltogether by welding to form a weld joint; priming an outer surface ofthe metal liner; wrapping the metal liner with a fiber winding layeraround the outer surface; applying a pressure to the metal liner fromwithin the cavity to oppose forces applied to the outer surface of themetal liner during the step of wrapping the metal liner; and heating thehybrid tank after wrapping the metal liner with the fiber winding layerto cure the hybrid tank.
 16. The method of claim 15, further comprisingwrapping the fiber winding layer helically and circumferentially withrespect to the longitudinal liner axis around the outer surface of theliner.
 17. The method of claim 15, further comprising positioning adiaphragm within the cavity and connecting to an inner diameter surfaceof the lower wall, the diaphragm separating the cavity into an upperportion and a lower portion, wherein the upper portion is for a gas andthe lower portion is for a liquid.
 18. The method claim 15, furthercomprising disposing a plastic liner radially between the diaphragm andthe lower wall, wherein the plastic liner corresponds in shape to thelower wall and is secured by an inner hoop ring to form a corrosionresistant volume in the lower portion for the liquid for a potable waterapplication.
 19. The method of claim 15, further comprising positioninga connector within an opening on the upper wall, the connector includinga collar that defines a longitudinal axis and an axial passage to allowthe air to enter the cavity, and defining a water connector in the lowerwall to allow water to enter the cavity.
 20. The method of claim 15,wherein the weld joint includes a weld bead extending radially outwardfrom the outer surface of the metal liner no more than approximately0.125 inches.